SC13003-C9001-U10-0002-Commissioning Plan Procedure For MBOP - 24-08-2015 PDF

PROJECT ENGINEERING DOCUMENT
DOCUMENT SUBMISSION STATUS:
00 28-AUG-15 FOR APPROVAL MP PSB PSB
REV DATE DESCRIPTION PREPARED CHKD APPD
OWNER
EPC CONTRACTOR CONSULTANT
PP-BETASURYA
PROJECT TITLE
120 MW Tanjung Uncang Combined Cycle Power Project,

Batam, Indonesia
BOP CONTRACTOR
DOCUMENT TITLE
COMMISSIONING PLAN & PROCEDURE FOR MBOP
DOCUMENT NO REV DATE PAGES
SC13003-C9001-U10-0002 00 28-AUG-15 70
CHAPTER 1
INTRODUCTION
This document provides the Commissioning Plan & Procedure with start-up sequence for the
Mechanical Balance of Plant equipments for the 120 MW CCPP.
The start-up and operation of the mechanical balance of plant equipments is based on the
requirements of the main plant machinery and is always in conjunction with the same. The sequence /
procedure provided here shall be altered or adjusted to the needs of the Main plant machinery and
equipments.
This document, hence, is not a complete procedure for the start-up of the power plant but only a small
part of the entire plant start-up sequence / procedure and needs to be read accordingly.
The Mechanical Balance of Plant system includes the following systems / components
Main Cooling water system

Auxiliary Cooling water system
Steam system
Feed Water system
Condensate system
Demin Water system
Potable Water system
Service Water system
Natural gas metering system
Compressed air system
Closed Drain and Vent system
Steam and Water Analysis System
Chemical Dosing System
Fire fighting system
Waste water treatment system
Electro Chlorination system
Nitrogen storage and purge system
Sea Water Intake System
PROJECT: 120MW COMBINED CYCLE POWER PLANT

PROJECTID: SC13003
TANJUNG UNCANG, INDONESIA
PREPAREDBY VERIFIEDBY APPROVEDBY DATE: 10.08.2015
MP PSB PSB SHEET: 2 of 70
For the start-up of the Power plant in the Simple Cycle Mode of Operation, the order of sequence for
the MBOP equipments / packages is envisaged to be as under -
1. Compressed air system
2. Auxiliary Cooling water system
3. Demin Water system
4. Natural gas metering system
5. Closed Drain and Vent system
Subsequently, for the Combined Cycle Mode of Operation of the Power plant, the order of sequence for
the other MBOP equipments / packages is envisaged to be as under -
6. Main Cooling water system
7. Balance of Demin Water System for Closed circuit cooling
8. Feed Water system
9. Condensate system
10. Steam system
11. Steam and Water Analysis System
12. Chemical Dosing System
For the start-up of the Power plant, the following MBOP equipments / packages are required to / can be
started independently, preferably before start of other activities, without any co-relation with any other
packages -
Potable Water system
Service Water system
Fire fighting system
Waste water treatment system
Nitrogen storage and purge system
MBOP SYSTEMS FOR SIMPLE CYCLE MODE OF OPERATION OF THE CCPP:
The following systems / packages are required to be commissioned and in operation to start the
Combined Cycle Power Plant in Simple-cycle mode -
A. COMPRESSED AIR SYSTEM :
Objective
The Plant Compressed Air system is supplied to provide / meet the service and instrument air
requirements of the CCPP, i.e. service air at various points in the power plant for cleaning /
maintenance purpose and instrument air for operation of control valves, solenoid valves, pneumatic
equipments, etc. The system consists of electrically operated air compressors (1 working + 1 standby)
for instrument air needs, 1 working electrically operated air compressor for service air needs, air driers
PROJECTID: SC13003
(1 working + 1 standby) for instrument air, air receivers (service air and instrument air) and all other
required auxiliaries and accessories.
Operating Philosophy
The air compressors are electrical motor driven with individual PLC control. There are 3 nos.
compressors and are programmed in the PLC to operate as per plant air requirement. The compressed
air from the service air compressor is fed to service air receiver from where all the service air
requirement of the plant is distributed. The compressed air from the instrument air compressors is fed
to the air driers, which remove the moisture from the air and make suitable for instrument
requirement. The dried air is fed to the instrument air receiver from where it is distributed to the entire
CCPP.
Reference Documents
- P&ID of Service and Instrument Air System (SC13003-4500-U01-0004)

- O&M Manual for Air Compressors
- O&M Manual for Air Driers
- O&M Manual for Instruments
Inputs Required for Commissioning / Operation of the System
The following inputs are required for the commissioning and operation of the system.
SN Input @ terminal point By Particulars / Remark

1 Electrical Power Compressor incomers ZUG 3 phase, 50 Hz, 400 V
(00QEA10-AN001, 00QEA10- supply
AN003&
00QEA10-AN003),
Air driers (00QEA10-AT001,
00QEA10-AT002)
2 Electrical Power 00QEB10-CG001 - ZUG 24 V DC
Solenoid valve inlet
3 Instrument Pressure transmitters ZUG 24 V DC
power / signal
4 Earthing All electrical equipments ZUG

PROJECTID: SC13003
Pre-Commissioning Checks
The following checks are required to be done before commissioning of the system.
SN Equipment Check How Remark

1 Air piping To inspect and check all Visual inspection
the joints in the air line
are complete
2 DCS connections To check connections of Visual inspection,
the instruments and continuity test, etc.
compressors to the DCS
3 Instrument Check the calibration Through individual 00QEB10CP003,
calibrations ranges / settings of all monitors / 00QEB10CP004,
the instruments communicators
4 Motor power (air Check the motor power Run the motor and
compressor) consumption on no load measure current flow
& load condition through multimeter
5 Air compressor PLC Check settings in the Use Manual to program
PLC of each compressor the PLC for the system
as per Manual set, operating, trip
pressures
6 Air drier Check settings in the Use Manual to program
controller of each drier the controller for the
as per Manual system operating timing
/ pressures
7 Valves Check the operation of Through manual 00QEB10CG001
the valves through override option and
manual operation and from DCS system
DCS
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
1. The air compressors to be powered from the panel room.

2. The air driers to be powered from the panel room.
3. The compressors to be started as per the O&M manual instructions.
4. The motor power consumption to be checked for unload / load operation.
5. The air to be charged and discharged to the service air receiver.
6. The piping to the service air receiver to be checked and air receiver to be pressurized to the
required pressure.
7. The air driers to be started and instrument air receiver to be charged with dry air.
8. The valves in the air lines to be opened and air to be circulated in the entire plant. Leakages to
be checked. Drains to be opened and lines to be flushed.
9. Individual air connections / valves to equipments to be checked at each location.

PROJECTID: SC13003
Closed Loop Checks
Alarms, closed loops, which are configured in the DCS, shall be checked after pre-commissioning and /
or commissioning before start of commercial operation.
The following alarms are to be checked in the DCS -
SN Tag No Equipment Indication type Remarks

1 00QEB10-CP003 Pressure transmitter Low Alarm
2 00QEB10-CP004 Pressure transmitter Low Alarm
The following closed loops are to be checked in the DCS -
SN Input Control Variable Control Logic

Measurement Action
1 00QEB10-CP004 00QEB10-CG001 On / Off In case if the instrument air
Pressure Solenoid valve Digital pressure falls below 9 bar(g), the
transmitter solenoid valve shall close and
stop service air flow to the
plant.
B. CLOSED COOLING WATER SYSTEM :

Objective
The function of the Closed Cooling Water (CCW) system is to provide a continuous supply of cooling
water to the Closed circuit cooling water (CCCW) heat exchangers for cooling of the following
consumers:
GTG lube oil and generator coolers (separate CCW system for each of the GTGs),
STG lube oil and generator coolers,
BFWPs (part of STG CCCW system),
HRSG re-circulation pumps (part of STG CCCW system)
CCW system removes the waste heat rejected in the above areas.
Each of the Closed Circuit Cooling Water systems (One system of GTG1, One system for GTG2, One
system for STG) consists of One (1) working and one (1) standby Cooling Circulation Water Pumps
(CCWP) along with drive motors to circulate the cooling water within the system, expansion tank, Fin
fan coolers (2 sets - 1 working + 1 standby) assembly, necessary piping and auxiliary systems.
One of the 2 nos. cooling circulation water pumps shall operate continuously, to circulate the cooling
water through one set of oil coolers and generator coolers of one GTG / STG and the Fin fan cooler
assembly at required pressure. The cooling water shall get heated to higher temperatures in the GTG /
STG coolers and this hot water shall be cooled back to lower temperatures in the Fin fan cooler
assembly, which consists of finned tube bundles and blowers to reject this heat into the atmosphere.

PROJECTID: SC13003
Reference Documents
- P&ID of Closed Cooling Water System (SC13003-C9001-U01-0007)
- O&M Manual for Fin Fan coolers

1 Electrical Power Fin Fan coolers for GTG1 ZUG 3 phase, 50 Hz, 400 V
(01PAE10-AH200A& 01PAE10- supply
AH200B), Fin Fan coolers for
GTG2 (02PAE10-AH200A&
02PAE10-AH200B), Fin Fan
coolers for STG (03PAE10-
AH200A& 03PAE10-AH200B),
Pumps of Fin Fan coolers for
GTG1 (01PGB10-AP110A&
01PGB10-AP110B), Pumps of Fin
Fan coolers for GTG2 (02PGB10-
AP120A& 02PGB10-AP120B),
Pumps of Fin Fan coolers for STG
(03PGB10-AP130A& 03PGB10-
AP130B)
2 Instrument ZUG 24 V DC
power / signal
3 Earthing ZUG

1 Water piping To inspect and check all the Visual inspection
joints in the lines are
complete
2 DCS connections To check connections of the Visual inspection,
pumps, instruments and the continuity test, etc.
valves to the DCS

PROJECTID: SC13003
3 Instrument Check the calibration ranges Through individual 01PGB10CT001,
calibrations / settings of all the monitors / 02PGB10CT001,
instruments communicators 03PGB10CT001,
01PGB10CP010,
02PGB10CP010,
03PGB10CP010,
01PGB10CF001,
02PGB10CF001,
03PGB10CF001
01GHC10-CL001,
02GHC10-CL001,
03GHC10-CL001
4 Motor power Check the motor power Run the motor and
consumption on no load measure current flow
condition (after de- through multimeter
coupling), and on load in
coupled condition.
5 Pumps Check alignment between Use GA dwg and O&M 01PGB10-AP110A,
the pumps & motors, check Manual to verify 01PGB10-AP110B,
flanged connections, seals, correctness of 02PGB10-AP120A,
foundation bolts sturdiness, installation 02PGB10-AP120B,
electrical connections, 03PGB10-AP130A,
direction of rotation, 03PGB10-AP130B
earthing, vibrations during
operation.
1. The closed circuit system shall be filled / topped up with fresh DM water from the DM water
system through the flow control valve bypass line. The topmost vent in the line shall be kept
open for venting of air trapped inside the lines.
2. Once the system is filled with DM water, the air inlet shall be charged through the pressure
control valve to achieve the desired pressure (say, 3 bar).
3. One of the circulating water pumps shall be turned on and the water shall be circulated in the
system.
4. Upon start of the GTG / STG, the return cooling water shall be hot. The fin fan coolers (3 nos. for
each set) shall be turned on to reduce the temperature to the desired level.
5. The water level in the expansion tank shall be maintained by the level control valve and the
pressure shall be maintained by the pressure control valve.
6. Individual valves at inlet of each of the equipments to be checked.
7. All alarms, interlocks and trips to be checked as per the list below.

PROJECTID: SC13003
Alarms, Interlocks and Trips Checks
Alarms, interlocks, trips, which are configured in the DCS, shall be checked after pre-commissioning and
/ or commissioning before start of commercial operation.
The following alarms to be checked in the DCS -

1 01PGB10-AP110A, Closed Circuit Cooling Trip Alarm
01PGB10-AP110B, Water Pumps for
02PGB10-AP110A, GTG1, GTG2 and STG
02PGB10-AP110B, respectively
03PGB10-AP110A,
03PGB10-AP110B
2 01PGB10-CF001, Flow transmitter Low flow Alarm
02PGB10-CF001,
03PGB10-CF001
3 01PGB10-CT001, Temperature High Alarm
02PGB10-CT001, transmitter
03PGB10-CT001
4 01GHC10-CL001, Level transmitter Low / High Alarm
02GHC10-CL001,
03GHC10-CL001
5 01GHC10-CP001, Pressure transmitter Low / High Alarm
02GHC10-CP001,
03GHC10-CP001
The following interlocks and trips to be checked in the DCS -

SN Tag No. Equipment Interlock / Trip Logic
with
1 01PGB10-AP110A, Closed Circuit Interlock with each Only one of the two
01PGB10-AP110B, Cooling Water other pumps to remain in
02PGB10-AP110A, Pumps for GTG1, operation. If one
02PGB10-AP110B, GTG2 and STG pump trips, other
03PGB10-AP110A, respectively pump should start
03PGB10-AP110B automatically,
provided interlocks
and healthy. Pumps
to have Auto /
Manual control
selection in DCS.
2 01GHC10-AA060, Flow control valve 01GHC10-CL001, The control valve
02GHC10-AA060, 02GHC10-CL001, shall close shut in
03GHC10-AA060 03GHC10-CL001 case of high level.
Level transmitter
3 01GHC10-AA001, Pressure control 01GHC10-CP001, The control valve
02GHC10-AA001, valve 02GHC10-CP001, shall shut close in
03GHC10-AA001 03GHC10-CP001 case of high
Pressure pressure.
transmitter

PROJECTID: SC13003
Checklist for Pumps :-
SN. TAG NO. EQUIPMENT CONFIRM

1 01PGB10-AP110A, Closed Circuit cooling water pump-1 for GTG 1
2 01PGB10-AP110B, Closed Circuit cooling water pump-2 for GTG1
3 02PGB10-AP110A, Closed Circuit cooling water pump-1 for STG
4 02PGB10-AP110B, Closed Circuit cooling water pump-2 for STG
5 03PGB10-AP110A, Closed Circuit cooling water pump-1 for GTG2
6 03PGB10-AP110B Closed Circuit cooling water pump-2 for GTG2
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps -.
SN Particular Check Confirm Remark

1 Foundation bolts Inspect and check the tightness of all
the foundation bolts
2 Alignment Check alignment of the pumps with
the motor using dial type gauge
3 Nozzle flanges Check the connections of the various
nozzles whether as per requirement
and whether tight
4 Couplings Check the installation of the coupling
and the tightness of the joints. Install
coupling guard.
5 Electrical Check that the electrical cabling in
Connections the terminal box is installed properly
and that connections are terminated
as per the requirement.
6 Motor power Check the motor power consumption
on no load condition (after de-
coupling), and then on load in
coupled condition.
7 Direction of Check the direction of rotation of the
rotation pump whether as per the
requirement.
8 Mechanical Seal Check the operation of the
mechanical seal and abnormality if
any.
9 Vibrations Check vibrations of the pump (either
touch or with portable vibration
sensor) are within acceptable ranges.
10 Noise Check the noise / sound of the pump
during operation for any abnormality
PROJECTID: SC13003
C. DEMIN WATER SYSTEM :
Objective
The Plant Demin water system is supplied to provide / meet all the De-mineralized water requirements
of the CCPP, ie. HRSG make-up feed water (through condensate tank), closed circuit cooling water
make-up, GTG washing water.
The system consists of -

- DM water make-up pumps (1 w + 1 s) to pump DM water from DM tank to various battery limits
in the CCPP with a rated flow of 15 m3/hr and pressure of 8 barg.
-
and all other required auxiliaries and accessories.
The DM water tank shall be filled and the normal operating level shall be maintained by operating one
of the DM water transfer pumps (located in the Water treatment plant) vide on-off operation based on
low and high level in the tank.
One of the DM water make-up pumps shall operate continuously to feed Demin water at various points
in the CCPP at required pressure. A flow control valve is installed to ensure minimum flow re-circulation
for the pump. The DM water make-up pump shall also have protection from dry run by providing
interlock with DM water tank level transmitter for extra low level trip.
Reference Documents
- P&ID of DM Water System (SC13003-C9001-U01-0013)

- O&M Manual for DM water pumps and motors
- O&M Manual for Control Valves

1 Electrical Power DM make-up pumps ZUG 3 phase, 50 Hz, 400 V
(00GHC10-AP110A, 00GHC10- supply
AP110B& 00GHC10-AP110C)
2 Instrument Pressure transmitters, level ZUG 24 V DC
power / signal transmitters, flow transmitters,
control valves
3 Instrument air At inlet of control valves ZUG @ 8 to 10 barg

PROJECTID: SC13003

1 DM water piping To inspect and check all Visual inspection
the joints in the line are
complete
the pumps, instruments continuity test, etc.
and the valves to the DCS
3 Instrument Check the calibration Through individual 00GCK10-CF001,
calibrations ranges / settings of all the monitors / 00GCF10-CL001,
instruments communicators 00GHC10-CF001,
00GHC10-CP005
coupled condition.
5 Pumps Check alignment between Use GA dwg and O&M 00GHC10-AP110A,
the pumps & motors, Manual to verify 00GHC10-AP110B,
check flanged connections, correctness of 00GHC10-AP110C
seals, foundation bolts installation
sturdiness, electrical
connections, direction of
rotation, earthing,
vibrations during
operation.
6 Valves Check the operation of the Through manual 00GHC10-CG001

valves through manual override option and
operation and through from DCS system
DCS

PROJECTID: SC13003
1. 2 nos. DM make-up pumps installed at the Demin tank shall be checked thoroughly first. Before
the start of the pumps, the suction valves to be turned open manually. All the necessary checks
required for the pumps to be carried out. (Details of the procedure / check list for pumps
provided separately below). The operation of the pumps locally as well as through DCS panel to
be checked.
2. Minimum re-circulation valve installed on the DM make-up pumps outlet return line shall be
checked for operation, locally and through DCS.
3. The calibration of the flow transmitters to be checked and connection to the DCS to be ensured.
4. The DM water piping to various points in the plant to be checked for leakages and supports.
5. The manual valves in the lines to be checked for proper operation. Leakages to be checked.
Drains to be opened and lines to be flushed.
Alarms, interlocks, trips, closed loops, which are configured in the DCS, shall be checked after pre-
commissioning and / or commissioning before start of commercial operation.

1 00GCF10-CL001 Tank level transmitter 4 to 20 mA Set point 3.0 m
Level low 2.0 m
Level extra low 1.0 m,
Level high 3.5 m,
Level extra high 3.8 m
2 00GHC10-AP110A DM make-up pump-1 Trip
3 00GHC10-AP110B DM make-up pump-2 Trip
4 00GHC10-CP005 Pressure transmitter 4 to 20 mA Pressure low 5 barg
The following closed loops are to be checked in the DCS for auto control action -

Measurement Action
1 00GCF10-CL001 DM transfer pump On/Off Based on tank level low and high
Tank level located in the WTP Digital signal signals, the pump shall be
transmitter started / stopped
2 00GHC10-CF001 00GHC10-CG001 Open/Close In case of pump flow less than
Flow transmitter Control valve Analog minimum (5 m3/hr), the valve
shall open proportionally and
maintain the minimum flow
through the pump

PROJECTID: SC13003
The following interlocks and trips are to be checked in the DCS -

with
1 00GHC10-AP110A& DM make-up pump- Interlock with Only one pump to
00GHC10-AP110B 1& each other remain in operation.
DM make-up pump-2 If one pump trips,
other pump should
start automatically.
Pumps to have Auto /
Manual control
selection in DCS.
2 00GHC10-AP110A& DM make-up pump- 00GCF10-CL001 In case of tank level
00GHC10-AP110B 1& DM Tank level extra low, the pump
DM make-up pump-2 transmitter in operation shall trip
and either pump
shall not turn on
(start-permissive)

PROJECTID: SC13003
Checklist for Pumps

1 00GHC10-AP110A DM Make Up Pump 1
2 00GHC10-AP110B DM Make Up Pump 2
3 00GHC10-AP110C DM Make Up Pump 3
pumps:-

and whether tight
coupling guard.
coupled condition.
requirement.
any.

PROJECTID: SC13003
Checklist for Pneumatic Control Valves

1 00GHC10-AA001 Globe Valve
pneumatic control valves -

1 Supports Inspect and check the sturdiness and
rigidness of the supports for each of
these valves
2 Actuator Check actuator fitment is intact and
has not loosened during
transportation / installation
and whether tight
4 Auxiliaries Check whether the valve auxiliaries
are installed, ie. Valve actuator
positioned, position feedback
transmitter, pointer
5 Electrical Check that the electrical power and
Connections signal cabling in the terminal box is
installed properly and that
connections are terminated as per
the requirement.
6 Pneumatic Check the connections of the
connections pneumatic instrument air for the
actuator, the pressure of the air, the
air release, etc.
7 Operation Check the operation of the valve
during on / off command from local
controller and from DCS and confirm.
8 Noise Check for any abnormal noise /
sound of the valve during operation

PROJECTID: SC13003
D. NATURAL GAS METERING SYSTEM :
Objective
The Natural Gas Conditioning and Metering system is provided to supply regulated pressure and
metered flow of Natural gas to the 2 nos. GTGs of the CCPP. The gas skid system consists of natural gas
meters, control valves, emergency shut-off valve, filters, and all other required auxiliaries and
accessories. Gas leakage detectors are also installed in the system for emergency shutdown of the plant
in case of any leakage of gas.
The emergency shut-off valve shall operate in case of emergency shut-down of the plant and in case of
any fire detection / gas leakage detection near the natural gas skid. The coalescing filters (1 working and
1 stand-by) shall filter all moisture and contaminants from the natural gas. The gas flow metes (1
working and 1 standby) shall continuously monitor and record the gas consumption of the CCPP. The
gas control valves (1 working and 1 hot standby) shall reduce and control the pressure of natural gas at
the outlet of the gas skid (to the inlet of gas compressors). Solenoid operated valves are provided to
select / control the working and standby equipments.
Note: All the instruments and electrical equipments in the system are designed for Ex-proof
classification, ie. IEC Zone 1, Group IIA/IIB, T3.
Reference Documents
- P&ID of Fuel Gas System (SC13003-4100-U01-0001)

- O&M Manual for Natural Gas Pressure Reducing & Metering Skid
- O&M Manual for Solenoid On/off Valves
- O&M Manual for Gas Flow meters
- O&M Manual for Gas leakage detectors
- O&M Manual for Filters

1 Electrical Power At the Skid Junction Box ZUG 1 phase, 50 Hz, 220 V
supply
control valves
3 Instrument air At inlet of skid header ZUG @ 8 to 10 barg

PROJECTID: SC13003

1 Natural Gas To inspect and check all Visual inspection and
piping the joints in the line are leakage test
complete
3 Instrument Check the calibration Through individual 00MBP10CP008,
calibrations ranges / settings of all monitors / 00MBP10CP006,
the instruments communicators 00MBP10CP001,
00MBP10CP013,
00MBP10CF001,
00MBP10CP011,
00MBP10CP016,
00MBP10CP009,
00MBP10CP010,
00MBP10CF001,
02MBA10CF001
4 Power Check the power supply Visual check and
connections to the skid continuity test
and individual
equipments
5 Instrument air Check instrument air is Visual check and
available at requisite through air pressure
pressure (8 barg) at the gauge
system inlet and various
components
6 Solenoid Check the operation of Through manual 00MBP10CG001,

operated the valves through override option and 00MBP10CG004,
On/Off Valves manual operation and from DCS system 00MBP10CG006,
through DCS 00MBP10CG008,
00MBP10CG005,
00MBP10CG007,
00MBP10CG003,
01MBA10CG100,
02MBA10CG200
7 Pneumatic Check the operation of Through manual
operated the valves through override option and
Control Valves manual operation and from DCS system
through DCS
8 Filters Check the cleanliness of Visual check and
the filters, clean the filter manual operation
screen, install and fix all
connections

PROJECTID: SC13003
1. The natural gas skid shall be checked thoroughly for completeness of all joints. All the necessary
checks required for the valves& filters to be carried out. (Details of the procedure / check list for
valves provided separately below).
2. The natural gas lines connecting the existing power plant to the new CCPP system to be checked
for any leakages. Pipe supports to also be checked whether properly and sufficiently installed.
3. Nitrogen gas purging shall be done to initially clean / purge the piping and system with inert gas
using the nitrogen purging system.
4. Interlocks for the emergency shut-off valve to be checked for proper operation.
5. Operation of all solenoid valves installed shall be checked thoroughly. Before the start of the
system, the manual valves to be turned open manually. All the necessary checks required for
the solenoid valves to be carried out. (Details of the procedure / check list for solenoid valves
provided separately below). The operation of these valves locally as well as through DCS panel
to be checked.
6. Coalescing filters to be cleaned, checked and installed back. Operation of drain valves, locally
and through DCS, to be checked.
7. The calibration of the flow meters to be checked and connection to the DCS to be ensured.
8. The gas leakage detection sensors cabling to DCS to be checked.
10. Individual valves at each of the equipments to be checked. Pressure safety valve operation to
be checked.


1 00MBP10-CG001 Emergency Shut-off valve On Emergency condition
2 00MBP10-CP008, Differential pressure High Alarm
00MBP10-CP011, transmitter
3 00MBP10-CP013, Pressure transmitter High / Low Alarm
00MBP10-CP016,
00MBP10-CP006,
00MBP10-CP009,
00MBP10-CP010
4 00MBP10CF001, Flow transmitter High / Low Alarm
01MBA10CG100,
02MBA10CG200
5 00MBP10-CB001, Gas leakage detectors On Alarm and
00MBP10-CB002 emergency shutdown

PROJECTID: SC13003

Measurement Action
1 Emergency plant 00MBP10-CG001 On / Off In case of external emergency
trip Emergency Shut-off Digital trip from operator
valve
2 00MBP10-CP013 00MBP10-CG002, Open / One of the control valves shall
Pressure 00MBP10-CG003 Close remain in operation and control
transmitter Control valve Analog outlet pressure of gas to 7.5
barg. In case outlet pressure fall
below the set pressure, the
other control valve shall
automatically take-over.
3 00MBP10-LS010A, 00MBP10-AT010A, On / Off In case of level switch signal
00MBP10-LS020B 00MBP10-AT010B Digital high, the solenoid valve shall
Level switch Solenoid valve operate and drain condensate
from the filter
SN Tag No. Equipment Interlock / Trip with Logic

1 00MBP10-CG004, Solenoid valve 00MBP10-CG001 In case of emergency
00MBP10-CG005, Emergency Shut-off shut-off valve operated,
00MBP10-CG006, valve solenoid valves shall
00MBP10-CG007 remain in off condition.
2 00MBP10-CG008 Solenoid valve 00MBP10-CG001 In case of emergency
00MBP10-CG001 Emergency Shut-off shut-off valve operated,
00MBP10-CG003 valve solenoid valve shall open.
01MBP10-CG100
02MBP10-CG200
3 00MBP10-CB001, 00MBP10- On / Off Digital Emergency shut-off valve
00MBP10-CB002 CG001 close in case of gas
Gas leakage detector Emergency leakage detector signal
Shut-off valve

PROJECTID: SC13003
Checklist for Solenoid operated Pneumatic On/Off Valves
solenoid operated pneumatic valves - 00MBP10-CG001

1 Supports Inspect and check the installation
these valves
and whether tight
are installed, ie. Valve actuator,
solenoid assembly, air connections,
etc.
the requirement.
air release, etc.

PROJECTID: SC13003

1 01MBA10-AA100 3-Piece Ball
2 02MBA10-AA200 3-Piece Ball
pneumatic control valves -

these valves
and whether tight
are installed, i.e. Valve actuator
the requirement.
air release, etc.

PROJECTID: SC13003
E. CLOSED DRAIN AND VENT SYSTEM :
Objective
The Closed drain and vent system is provided to safely vent and drain all the vent gases / drains from
the plant. The system consists of closed drain drums (2 nos.) and all required auxiliaries and accessories.
The vent and condensate drains from the plant are connected to the closed drain drum, where the
filters separate out the gases and condensate. The gases escape to the vent stack and the condensate is
drained out via a condensate pump. The condensate level in the tank shall be maintained through a
level switch which shall operate the drain pump to drain out the condensate into the WWTP. Additional
sump (submersible) pump is also installed in the pit to pump the rain water / drains into the WWTP.
Note: All the instruments and electrical equipments in the system are designed for Ex-proof
classification, i.e. IEC Zone 1, Group IIA/IIB, T3.
Reference Documents
- P&ID of Closed Drain and Vent System (SC13003-P5003-U01-0003)

- O&M Manual for Condensate pumps and motors
- O&M Manual for Closed Drain Drum

1 Electrical Power Condensate pumps - (00GMA10- ZUG 3 phase, 50 Hz, 400 V
AP110, 00GMA10-AP120), supply
Sump pumps (submersible
pumps) (00GMA10-AP210,
00GMA10-AP220)
power / signal switches

PROJECTID: SC13003

1 Natural gas ventTo inspect and check all Visual inspection
and drain pipingthe joints in the line are
complete up to the vent
stack
the pumps and actual operation,
instruments to the DCS continuity test, etc.
3 Instrument Check the calibration Through individual 01GMA10-PS001,
calibrations ranges / settings of all monitors / 02GMA10-PS002,
the instruments communicators 01GMA10-CL001,
02GMA10-CL002
4 Pump Motor Check the motor power Run the motor and
power consumption on no load measure current flow
condition and on load through multi meter
condition.
5 Pumps Check alignment Use GA dwg and O&M 00GMA10-AP110
between the pumps & Manual to verify
motors, check flanged correctness of
connections, seals, installation
foundation bolts
rotation, earthing,
vibrations during
operation.
6 Filters Check the condition and Through manual check
correctness of
installation of the filters
in the closed drain drum
7 Initial fill of DM Initially before starting This is required for
water the plant, fill the Closed checking operation of
drain drums with DM the pumps and for
water up to the normal sealing of the gas from
level through the vent entering in to the
openings condensate pumps
1. There are 2 nos. of closed drain drums in the plant with all the natural gas drains and vents
connected to the same.

PROJECTID: SC13003
2. The gas lines and drain lines connecting the various points to the Closed drain drums to be
checked for any leakages. Pipe supports to also be checked whether properly and sufficiently
installed.
3. Initially before starting the plant, fill the Closed drain drums with DM water up to the
normal level through the vent openings manually. This is required for checking
operation of the pumps and for sealing of the gas from entering in to the condensate
pumps.
4. A condensate pump is installed at the outlet of each closed drain drum. All the necessary checks
required for the pumps to be carried out. (Details of the procedure / check list for pumps
be checked.
5. Interlocks of the condensate pumps with the closed drain drum level switch to be checked.
Level switch to be calibrated and checked for proper operation.
6. Differential pressure transmitter / signal to be calibrated and configured in the DCS.
7. The calibration of the transmitters to be checked and connection to the DCS to be ensured.
9. All alarms, interlocks, trips and loops to be checked as per the list below.
10. Each closed drain drum pit is also provided with submersible (sump) pump to drain out water
collected in the pit. This pump is auto on/off pump with control panel and its operation shall be
checked for correctness of operation. (Details of the procedure / check list for pumps provided
separately below).
Alarms, closed loops, which are configured in the DCS, shall be checked after pre-commissioning and /
or commissioning before start of commercial operation.

1 01GMA10-PS001, Differential pressure High Alarm
02GMA10-PS002 switch
2 01GMA10-CL001, Level switch High Alarm
02GMA10-CL002

Measurement Action
1 01GMA10-CL001, 00GMA10-AP110, On / Off In case of the level switch low /
02GMA10-CL002 00GMA10-AP120 Digital high signal, the condensate
Level switch Condensate pump pump shall turn off / on resp.
2 Inbuilt level 00GMA10-AP210, On / Off In case the rain water / drain
sensor 00GMA10-AP220 through level in the pit is low / high, the
Sump pump local control pump shall turn off / on.
panel of
pump
PROJECTID: SC13003
Checklist for Pumps

1 00GMA10-AP110 Condensate Pump
pumps -

and whether tight
coupling guard.
coupled condition.
requirement.
any.
ADDITIONAL MBOP SYSTEMS FOR COMBINED CYCLE MODE OF OPERATION OF THE CCPP:
The following additional systems / packages are required to be commissioned and in operation to start
the Combined Cycle Power Plant in Combined-cycle mode -

PROJECTID: SC13003
F. MAIN COOLING WATER SYSTEM :
Objective
The function of the cooling water system is to condense the steam received by the condenser from the
exhaust of steam turbine. The cold water shall be pumped through the condenser by Centrifugal type
Cooling water pumps where the cold water shall pick up the latent heat delivered by the condensation
of steam. This hot water returning from the Condenser shall be cooled in a Cooling tower designed for
sea water application.
This system consists of 2 (two)nos. (1w+1s)x 100% capacity of (Main Cooling Water) MCW pumps along
with electrical drive motors that shall pump sea water from existing header at a pressure of 2.5 bar(g) at
pump outlet to the condenser and back to the Cooling tower.
One of the 2 nos. main cooling water pumps shall operate continuously to feed sea water for cooling
requirement of the steam condenser in the CCPP at required pressure. The other pump shall remain as
standby. Each of the pumps shall have protection from dry run with the help of a suction pressure
transmitter. A differential pressure switch is also installed across the inlet strainer for indication of
cleaning time.
Reference Documents
- P&ID of Main Cooling Water System (SC13003-C9001-U01-0008)

- O&M Manual for Main Cooling water pumps and motors
- O&M Manual for Butterfly valves

1 Electrical Power Main Cooling Water pumps ABB 3 phase, 50 Hz, 6 kV
(00PAD10-AP110A, 00PAD10- supply
AP110B),
Motorized On/Off Butterfly
Isolation valve (00PAD10- 3 phase, 50 Hz, 400 V
CG105, 00PAD10-CG106, supply
00PAD10-CG108, 00PAD10-
CG109, 00PAD10-CG110,
00PAD10-CG111)
2 Instrument Pressure transmitters, ABB 24 V DC
power / signal differential pressure
transmitters, pressure switches
3 Earthing All electrical equipments ABB

PROJECTID: SC13003

1 Sea water To inspect and check all Visual inspection
piping the joints in the lines are
complete
2 DCS To check connections of Visual inspection,
connections the pumps, instruments continuity test, etc.
3 Instrument Check the calibration Through individual 00PAD10CP007,
calibrations ranges / settings of all the monitors / 00PAD10CF001,
instruments communicators 00PAD10CP044,
00PAD10CP045
4 Motor power Check the motor power Run the motor and Winding
consumption on no load measure current flow temperature &
condition (after de- through multimeter Bearing
coupling), and on load in temperature
coupled condition. RTDs connections
to be checked
5 Pumps Check alignment between Use GA dwg and O&M 00PAD10-
the pumps & motors, Manual to verify AP110A,
check flanged correctness of 00PAD10-
connections, seals, installation AP110B
foundation bolts
rotation, earthing,
vibrations during
operation.
6 Valves Check the operation of the Through manual 00PAD10CG105,
valves through manual override option and 00PAD10CG106,
operation and through from DCS system 00PAD10CG108,
DCS 00PAD10CG109
1. The Cooling tower shall first be commissioned as per the procedure described elsewhere in this
document / annexure.
2. The operation of the main cooling water pumps to be checked locally and from the DCS room.
3. The operation of the inlet / outlet valves of the pumps, inlet / outlet valves at the surface
condenser, (through operator console of valve actuator) and through DCS from the DCS room.
4. The main sea water piping to the surface condenser to be checked for leakages and supports.
5. The manual drain / vent valves in the lines to be checked for proper operation. Leakages to be
checked. Drains to be opened and lines to be flushed.

PROJECTID: SC13003

1 00PAD10-AP110A Main Cooling water Trip Alarm
pump 1
2 00PAD10-AP110B Main Cooling water Trip Alarm
pump 2
3 00PAD10-CP007 Pressure transmitter Low Low pressure alarm
4 00PAD10-CF001 Flow transmitter Low Low pressure alarm
5 00PAD10-CP044, Differential Pressure High Alarm
00PAD10-CP045 Transmitter
The following interlocks and trips are required to be checked in the DCS -

with
1 00PAD10-AP110A, Main Cooling water Interlock with Only one pump to
00PAD10-AP110B, pumps 1,2 each other remain in operation.
If one pump trips,
other pump should
start automatically,
provided interlocks
and healthy. Pumps
to have Auto /
Manual control
selection in DCS.
2 00PAD10-AP110A, Main Cooling water Pressure Other pump shall
00PAD10-AP110B, pumps 1,2 transmitter turn on if the
00PAD10-CP007 pressure transmitter
shows lower
pressure.
4 00PAD10-CG105, Pump discharge valves 00PAD10-AP110A, The discharge valve
00PAD10-CG106, 00PAD10-AP110B, shall turn Open 15
00PAD10-CG108, seconds after the
00PAD10-CG109 pump is turned On.

PROJECTID: SC13003
Checklist for Pumps

1 00PAD10-AP110A Main Cooling Water Pump-1
2 00PAD10-AP110A Main Cooling Water Pump-2
pumps -

and whether tight
coupling guard.
coupled condition.
requirement.
any.

PROJECTID: SC13003
Checklist for Motorized Valves

1 00PAD10-AA105 Butterfly Valve
motorized valves -.

these valves
2 Actuator Check if any support is provided /
required for the actuator
and whether tight
4 Couplings / Joints Check the tightness of the coupling /
flange of the actuator with the valve
gearbox
the requirement.
6 Actuator motor Check the actuator motor power
power consumption during on-off operation
of the valve using multi-meter
7 Direction of Check the operation of the valve
rotation / during on / off command from local
operation controller and from DCS and confirm.

PROJECTID: SC13003
G. SEA WATER COOLING TOWER:
Objective
The circulating cooling water which get heated in the Surface Condenser of the STG is supposed to be
cooled back to normal temperature. This is done in a Cooling tower. Since the water used for cooling is
sea water for this project, the cooling tower is designed for cooling of circulating sea water using
atmospheric air and forced draft fans.
The system consists of -

- Cooling tower elements / fills and its supporting structure
- Cooling tower fans assembly
- RCC structure for holding cooling tower elements
- Basin water level control system
and all other required auxiliaries and accessories.
Refer Separate Annexure for the same.
Reference Documents
- P&ID of Sea Water Cooling Tower (SC13003-C9001-U01-0008)

- O&M Manual for Sea water Cooling tower
Checklist for Fans

PROJECTID: SC13003
pumps -

1 Foundation bolts
2 Alignment
3 Nozzle flanges
4 Couplings
5 Electrical
Connections
6 Motor power
7 Direction of
rotation
8 Mechanical Seal
9 Vibrations
10 Noise

PROJECTID: SC13003
H. FEED WATER SYSTEM :
Objective
The Feed Water system is provided to supply feed water to the HRSGs for production of high pressure
steam. The system consists of boiler feed water pumps (BFWPs), to pump feed water from deaerator to
the HP drum), and all other required auxiliaries and accessories.
One nos. working and one nos. standby BFWPs are provided for each HRSG with a rated flow of 78
m3/hr and head of 1018 m. One of the 2 nos. BFWPs shall operate continuously to supply high pressure
feed water to the HP steam drum at required pressure. The other pump shall remain as standby. Each
of the pumps shall have protection from dry run with the help of level transmitter signal from the LP
Drum (deaerator). A differential pressure switch is also installed across the inlet strainer for indication
of strainer choking and hence safe operation of the pumps.
Reference Documents
- P&ID of Feed Water System (SC13003-P5002-U01-0012)

- O&M Manual for Boiler Feed water pumps and motors
- O&M Manual for Motorized Gate valves

1 Electrical Power HRSG Boiler Feed Water pumps ZUG 3 phase, 50 Hz, 6 kV
(01LAB10-AP110A, 01LAB10- supply
AP110B, 02LAB10-AP110A,
02LAB10-AP110B)
Motorized On/Off Gate valves - 3 phase, 50 Hz, 400 V
(01LAB10-CG101, 01LAB10- supply
CG102, 01LAB10-CG103,
01LAB10-CG104, 02LAB10-
CG101, 02LAB10-CG102,
02LAB10-CG103, 02LAB10-
CG104)
2 Instrument Pressure transmitters, ZUG 24 V DC
power / signal differential pressure
transmitters, pressure switches

PROJECTID: SC13003

1 Sea water To inspect and check all the Visual inspection
piping joints in the lines are
complete
2 DCS To check connections of Visual inspection,
connections the pumps, instruments continuity test, etc.
3 Instrument Check the calibration Through individual 01LAB10-CP002,
calibrations ranges / settings of all the monitors / 01LAB10-CP006,
instruments communicators 02LAB10-CP002,
02LAB10-CP006,
01LAB10-CP500,
01LAB10-CP501,
02LAB10-CP500,
02LAB10-CP501,
01LAB10-CP001
02LAB10-CP001
4 Motor power Check the motor power Run the motor and Winding
consumption on no load measure current flow temperature &
condition (after de- through multimeter Bearing
coupling), and on load in temperature RTDs
coupled condition. connections to be
checked
5 Pumps Check alignment between Use GA dwg and O&M 01LAB10-AP110A,
the pumps & motors, check Manual to verify 01LAB10-AP110B,
flanged connections, seals, correctness of 02LAB10-AP110A,
foundation bolts installation 02LAB10-AP110B
rotation, earthing,
vibrations during
operation.

PROJECTID: SC13003
6 Valves Check the operation of the Through manual 00PAD10-CG091,
valves through manual override option and 00PAD10-CG092,
operation and through DCS from DCS system 00PAD10-CG102,
00PAD10-CG103,
00PAD10-CG104,
00PAD10-CG105,
00PAD10-CG106,
00PAD10-CG107,
00PAD10-CG113,
00PAD10-CG114,
00PAD10-CG108,
00PAD10-CG109,
00PAD10-
CG110,00PAD10-
CG111, 00PAD10-
CP112
01LAB10CG101,
01LAB10CG102,
01LAB10CG103,
01LAB10CG104,
02LAB10CG101,
02LAB10CG102,
02LAB10CG103,
02LAB10CG104
1. All the motorized valves in the lines to be checked for operation locally (through operator
console of valve actuator) and through DCS from the DCS room. (Details of the procedure /
check list for motorized valves provided separately below).
2. The operation of the Boiler feed water pumps to be checked locally and from the DCS room.
(Details of the procedure / check list for pumps provided separately below).
3. The bearing temperatures of the pumps and motors, winding temperatures of the motors ,
mechanical seals, balancing lines, vibrations, etc. to be checked as per pump requirement.
4. The operation of the Auto minimum re-circulation valve of each of the pumps to be checked as
per the O&M manuals.
5. The feed water piping from and to various points to be checked for leakages and supports.
6. The manual drain / vent valves in the lines to be checked for proper operation. Leakages to be
checked. Drains to be opened and lines to be flushed before start of the pumps.

PROJECTID: SC13003

1 01LAB10-AP110A HRSG-1 BFWP -1 Trip Alarm
2 01LAB10-AP110B HRSG-1 BFWP - 2 Trip Alarm
3 02LAB10-AP110A HRSG-2 BFWP -1 Trip Alarm
4 02LAB10-AP110B HRSG-2 BFWP - 2 Trip Alarm
5 01LAB10-CP002, Differential pressure High Alarm
01LAB10-CP006, transmitter
02LAB10-CP002,
02LAB10-CP006
6 01LAB10-CP500, Pressure switch Low Alarm
01LAB10-CP501,
02LAB10-CP500,
02LAB10-CP501
7 01LAB10-CP001 Pressure transmitter Low Alarm
02LAB10-CP001

PROJECTID: SC13003

with
1 01LAB10-AP110A, HRSG-1 BFWP 1& 2 Interlock with Only one pump to
01LAB10-AP110B each other remain in operation. If
one pump trips, other
pump should start
automatically, provided
interlocks and healthy.
Manual control
selection in DCS.
2 01LAB10-AP110A, HRSG-1 BFWP 1& 2 Interlock with Pumps shall turn on only
01LAB10-AP110B Deaerator level if the level in deaerator
transmitter, is normal. Pumps shall
01HAD20CL001 trip if deaerator level is
very low.
3 01LAB10-AP110A, HRSG-1 BFWP 1& 2 01LAB10-CG101, Pump shall turn on only
01LAB10-AP110B 01LAB10-CG102 if its inlet valve is in
Open condition.
4 01LAB10-AP110A, HRSG-1 BFWP 1& 2 01LAB10-CG103, The discharge valve shall
01LAB10-AP110B 01LAB10-CG104 turn Open 25 seconds
after the pump is turned
On.
5 02LAB10-AP110A, HRSG-2 BFWP 1&2 Interlock with Only one pump to
02LAB10-AP110B each other remain in operation. If
one pump trips, other
pump should start
automatically, provided
interlocks and healthy.
Manual control
selection in DCS.
6 02LAB10-AP110A, HRSG-2 BFWP 1& 2 Interlock with Pumps shall turn on only
02LAB10-AP110B Deaerator level if the level in deaerator
transmitter, is normal. Pumps shall
02HAD20CL001 trip if deaerator level is
very low.
7 02LAB10-AP110A, HRSG-2 BFWP 1& 2 02LAB10-CG101, Pump shall turn on only
02LAB10-AP110B 02LAB10-CG102, if its inlet valve is in
Open condition.
8 02LAB10-AP110A, HRSG-2 BFWP 1& 2 02LAB10-CG103, The discharge valve shall
02LAB10-AP110B 02LAB10-CG104 turn Open 30 seconds
after the pump is turned
On.

PROJECTID: SC13003
Checklist for Pumps

1 01LAB10-AP110A Boiler feed water pump
2 01LAB10-AP110B Boiler feed water pump
3 02LAB10-AP110A Boiler feed water pump
4 02LAB10-AP110B Boiler feed water pump
pumps - 01LAB10-AP110A.

and whether tight
coupling guard.
coupled condition.
requirement.
any.

PROJECTID: SC13003

1 01LAB10-AA03001 Gate Valve
motorized valves - 01LAB10-CG101.

these valves
and whether tight
gearbox
the requirement.

PROJECTID: SC13003
I. CONDENSATE SYSTEM :
NA

PROJECTID: SC13003
J. STEAM SYSTEM :
Objective
The Steam system portion of the MBOP is supplied to meet the on / off and auxiliary steam
requirements of the CCPP. The system consists of motorized operated on / off steam valves, flow
meters, and all other required auxiliaries and accessories.
Based on the operation requirement of the HRSGs and the STG, the valves shall be turned on / off to
meet the steam requirements of the main and auxiliary equipments.
Reference Documents
- P&ID of Steam System (SC13003-P5001-U01-0015)

- O&M Manual for Turbine Bypass PRDSH station
- O&M Manual for Motorized Valves

1 Electrical Power Motorized Isolation on/off Gate ZUG 3 phase, 50 Hz, 400 V
valves - (03LBA10-CG101, supply
03LBA10-CG102, 03QHE10-
CG010, 03QHE10-CG011)
2 Instrument Flow transmitters, pressure ZUG 24 V DC

power / signal transmitters, temperature
transmitters, control valves

PROJECTID: SC13003

1 Steam piping To inspect and check all Visual inspection
complete as per the code
2 Steam line To clean the steam lines As per the boiler
blowing by blowing steam as per vendor procedure
the standard procedure
of boiler vendor
4 Instrument Check the calibration Through individual 03LAE10-CF010,
calibrations ranges / settings of all monitors / 03LAE20-CF010,
the instruments communicators 03LAE10-CP201,
03LAE20-CP201,
03LAE10-CT201,
03LAE20-CT201,
03LBA10-CF001,
03LBA10-CF002,
03LBB10-CF001,
03LBB10-CF002,
03LBA10-CP410,
03LCA40-CP410,
03UMA10-CT410,
03LCA40-CT410,
03LBA20-CP010,
03LBB10-CT401,
03LBA10-CP401,
ST1LBA20-CP010,
ST1LBA20-CP020
5 Valves Check the operation of Through manual 03MAB10-CG010,
the valves through override option and 03MAB20-CG010,
manual operation and from DCS system 03LAE10-CG011,
through DCS 03LAE20-CG011,
03LAE10-CG010,
03LAE20-CG010,
03LBA10-CG101,
03LBA10-CG102,
03QHE10-CG010,
03QHE10-CG011,
03LBA20-CG010

PROJECTID: SC13003
1. The Steam lines connecting the HRSGs to the STG system to be checked as per the ASME code.
Pipe supports to also be checked whether properly and correctly installed.
2. Operation of the control valves station (turbine bypass PRDSH station) to be checked, locally
and through DCS. (Details of the procedure / check list for pneumatic control valves provided
separately below and also PRDSH vendor Manual to be followed).
3. Operation of the motorized valves to be checked, locally and through DCS. (Details of the
procedure / check list for motorized valves provided separately below).
Drains to be opened and lines to be flushed initially.

1 03LAE10-CP201, Pressure transmitter High Alarm
03LAE20-CP201
2 03LAE10-CT201, Temperature transmitter High Alarm
03LAE20-CT201

Measurement Action
1 03LAE10-CP201, 03MAB10-CG010, Open / The PRDSH valve shall open /
03LAE20-CP201 03MAB20-CG010 Close close to control the outlet steam
Pressure PRDSH valve Analog pressure to 2 barg based on
transmitter input from press. transmitter.
2 03LAE10-CT201, 03LAE10-CG011, Open / The WCV valve shall open /
03LAE20-CT201 03LAE20-CG011 Close close to control the outlet steam
Temperature Water Control valve Analog temperature to 145oC based on
transmitter input from temp. transmitter.
3 03LBA20-CP010 03LBA20-CG010 Open / The PRDSH valve shall open /
Pressure Ejector steam Close close to control the outlet steam
transmitter Pressure Control Analog pressure to ?barg based on
valve input from press. transmitter.

PROJECTID: SC13003

with
1 03MAB10-CG010, HP PRDSH station Steam turbine trip HP PRDSH station to
03LAE10-CG011 operate if STG trips
(logic to be decided
by Siemens / SNCL)
2 03MAB20-CG010, LP PRDSH station Steam turbine trip LP PRDSH station to
03LAE20-CG011 operate if STG trips
(logic to be decided
by Siemens / SNCL)
Checklist for Pneumatic Control Valves (PRDSH Station)

1 ST1LBA20-AA010 Globe Valve
2 ST1LBA20-AA020 Globe Valve
pneumatic control valves - 03MAB10-CG010
these valves
and whether tight
are installed, ie. Valve actuator
the requirement.
air release, etc.
PROJECTID: SC13003
motorized valves - 03LBA10-CG101.

these valves
and whether tight
gearbox
the requirement.

PROJECTID: SC13003
K. STEAM AND WATER ANALYSIS SYSTEM :
Objective
The Steam and Water Analysis (SWAS) system is provided to monitor the pH, Conductivity, Silica,
dissolved Oxygen, Iron content in feed water, condensate and steam circuit of the HRSG in the CCPP.
The system consists of a packaged panel mounted system consisting of sample coolers, analyzers,
refrigerant system for cooling, etc. and all other required auxiliaries and accessories.
The Steam and Water analysis system automatically draws out sample from various points connected to
the HRSG feed water and steam circuits and with the help of analyzers, provides all the above data to
the plant DCS for indication and alarms. Normal cooling water is first used for cooling the samples and
followed by refrigerated cooling to maintain sample temperature to </=25oC.
Reference Documents
- P&ID of SWAS System (SC13003-C9001-U01-0021)

- O&M Manual for SWAS system
- O&M Manual for Instruments in the SWAS system

1 Electrical Power SWAS system ZUG 1 phase, 50 Hz, 220 V
supply
2 Instrument / SWAS system ZUG 1 phase, 50 Hz, 220 V
signal supply

1 Sampling piping To inspect and check all Visual inspection
complete as per the code
2 Closed circuit To inspect and check all Visual inspection
Cooling water the joints in the line are
piping complete
the instruments to the continuity test, etc.
DCS
PROJECTID: SC13003
4 Instrument Check the calibration Through individual pH analyzers,
calibrations ranges / settings of all monitors / Conductivity
the instruments communicators analyzers,
Dissolved Oxygen
Analyzers
1. The sampling lines connecting the SWAS system to various points in the plant to be checked as
per code. Pipe supports to also be checked whether properly and correctly installed.
2. Closed Circuit Cooling water lines connecting the SWAS system to be checked as per the
requirement. Pipe supports to also be checked whether properly and correctly installed.
6. O&M Manual shall be followed for commissioning of the SWAS system.

1 All tags Analyzers High Alarm
2 00QKA10-AN100 Chiller Trip Alarm

Measurement Action
1 01QUH10-QP002, 01QCA10-AP100/200 4 to 20 mA Based on the pH in the LP
02QUH10-QP002, 02QCA10-AP100/200 Analog drum and the HP drum, the
01QUH20-QP002, 01QCC10-AP100/200 speed of the LP and HP
02QUH20-QP002 02QCA10-AP100/200 dosing pumps shall be
pH Analyzers pH Dosing pumps varied.
Checklist for SWAS equipments
The minimum checks required to be done for the pre-commissioning and commissioning of the SWAS
system shall be done as per SWAS O&M manual.

PROJECTID: SC13003
L. CHEMICAL DOSING SYSTEM :
Objective
The Chemical Dosing System (HP and LP) is provided to dose respective chemicals (for pH correction and
Oxygen scavenging) in the HRSG of the CCPP. The system consists of a packaged skid mounted units
consisting of dosing tank, stirrer, dosing pumps, valves, and all other required auxiliaries and
accessories.
The Chemical dosing tanks shall be filled with respective solutions (chemicals) manually and ensured
that the tanks are always full (with the help of level gauge). A stirrer in the tank ensures that the
solution is always homogenous and flow able. The dosing pumps are positive displacement pumps that
dose small amount of the chemical in the respective circuit. The quantity of chemical is varied based on
the requirement by varying the speed of the pump with the help of variable frequency drive. There are
2 nos. LP dosing systems for oxygen scavenging and pH dosing in LP drum, and 1 no. HP dosing system
for pH correction in HP drum.
Reference Documents
- P&ID of Chemical Dosing System (SC13003-C9001-U01-0019)

- O&M Manual for Dosing Skid
- O&M Manual for Dosing pumps& motors

1 Electrical Power Dosing pumps - (01QLC10- ZUG 3 phase, 50 Hz, 400 V
AP100, 01QLC10-AP200, supply
02QLC10-AP100, 02QLC10-
AP200, 01QCA10-AP100,
01QCA10-AP200, 02QCA10-
AP100, 02QCA10-AP200,
01QCC10-AP100, 01QCC10-
AP200, 02QCA10-AP100,
02QCA10-AP200)
Stirrer motors (00QLC10-
AM100, 00QCA10-AM100,
00QCC10-AM100)

PROJECTID: SC13003

1 Chemical Dosing To inspect and check all Visual inspection
piping the joints in the line are
complete
the pumps to the DCS operation test, etc.
coupled condition.
4 Pumps Check alignment Use GA dwg and O&M
between the pumps & Manual to verify
motors, check flanged correctness of
connections, seals, installation
foundation bolts
rotation, earthing,
vibrations during
operation.
1. There are three (3) types of dosing chemicals to be dosed in both the HRSGs, ie. there are 2 nos.
of LP dosing skids and 1 no. HP dosing skid. Each of the skid is provided with 2 pumps for each
HRSG.
2. The dosing lines connecting the dosing system to the various points in the plant system to be
installed.
3. Dosing installed at the dosing skids shall be checked thoroughly first. Before the start of the
pumps, the suction valves to be turned open manually. All the necessary checks required for the
pumps to be carried out. (Details of the procedure / check list for pumps provided separately
below). The operation of the pumps locally as well as through DCS panel to be checked.

PROJECTID: SC13003

1 All above tags Pumps and Stirrers Trip Alarm

with
1 01QLC10-AP100, Dosing pumps HRSG 1 Trip & Dosing pumps to trip
01QLC10-AP200, HRSG 2 Trip in case if
02QLC10-AP100, corresponding HRSG
02QLC10-AP200, trips.
01QCA10-AP100,
01QCA10-AP200,
02QCA10-AP100,
02QCA10-AP200,
01QCC10-AP100,
01QCC10-AP200,
02QCA10-AP100
02QCA10-AP200

PROJECTID: SC13003
Checklist for Pumps
pumps -01QLC10-AP100, 01QLC10-AP200.

and whether tight
coupling guard.
coupled condition.
requirement.
any.
MBOP SYSTEMS TO BE COMMISSIONED INDEPENDENTLY:
The following MBOP systems / packages can be commissioned independently and shall be in operation
during the Simple as well as Combined Cycle mode of operation of the Power Plant -

PROJECTID: SC13003
M. POTABLE WATER SYSTEM :
Objective
The Plant Potable water system is supplied to provide / meet the potable water requirements of the
CCPP, ie. at warehouse, workshop, guard house, admin building, switchyard. The system consists of
potable water storage tank, potable water pumps (1 w + 1 s) to pump potable water from tank to
various battery limits in the CCPP with a rated flow of 4 m3/hr and pressure of 5.5barg, and all other
required auxiliaries and accessories.
The Potable water tank shall be filled and the normal operating level shall be maintained by a flow
control valve at inlet based on level transmitter measurement in the tank. One of the potable water
pumps (installed on the tank) shall operate continuously to feed potable water at various points in the
CCPP at required pressure. A flow control valve is installed to ensure minimum flow re-circulation for
the pump. The pump shall also have protection from dry run by providing interlock with tank level
transmitter for extra low level trip.
Reference Documents
- P&ID of Potable Water System(SC13003-C9001-U01-0017)

- O&M Manual for Potable water pumps and motors

1 Electrical Power Potable water pumps - ZUG 3 phase, 50 Hz, 400 V
(00GKB10-AP110A, 00GKB10- supply
AP110B)
control valves

PROJECTID: SC13003

1 Potable water To inspect and check all Visual inspection
piping the joints in the line are
complete
3 Instrument Check the calibration Through individual 00GKB10-CF001,
calibrations ranges / settings of all monitors / 00GKB10-CL001,
the instruments communicators 00GKB10-CP005
coupled condition.
5 Pumps Check alignment Use GA dwg and O&M 00GKB10-
between the pumps & Manual to verify AP110A,
motors, check flanged correctness of 00GKB10-
connections, seals, installation AP110B
foundation bolts
rotation, earthing,
vibrations during
operation.
6 Valves Check the operation of Through manual 00GKB10-CG001,
the valves through override option and 00GKC10-CG001
manual operation and from DCS system
through DCS
1. The Potable water tank is fed with service water tapped from the existing service water
pipeline.
2. Operation of the inlet control valve station to be checked, locally and through DCS. (Details of
the procedure / check list for pneumatic control valves provided separately below).
3. The potable water line connecting the tie-in point to the new CCPP potable water tank to be
installed.
4. 2 nos. Potable water pumps installed at the Potable water tank shall be checked thoroughly
first. Before the start of the pumps, the suction valves to be turned open manually. All the
necessary checks required for the pumps to be carried out. (Details of the procedure / check list

PROJECTID: SC13003
for pumps provided separately below). The operation of the pumps locally as well as through
DCS panel to be checked.
5. Minimum re-circulation valve installed on the pumps outlet return line shall be checked for
operation, locally and through DCS. (Details of the procedure / check list for pneumatic control
7. The potable water piping to various points in the plant to be checked for leakages and supports.

1 00GKB10-AP110A Potable water pump-1 Trip
2 00GKB10-AP110B Potable water pump-2 Trip
3 00GKB10-CL001 Tank level transmitter 4 to 20 mA Set point 2.0 m
Level low 1.5 m
Level high 2.5 m,
4 00GHC10-CP005 Pressure transmitter 4 to 20 mA Pressure low 3 barg

Measurement Action
1 00GKB10- 00GKC10-CG001 Open/Close Based on tank level low and high
CL001Tank level Control valve Analog signals, the control valve shall
transmitter open / close
2 00GKB10- 00GKB10-CG001 Open/Close In case of pump flow less than
CF001Flow Control valve Analog minimum (3 m3/hr), the valve
transmitter shall open proportionally and
through the pump

PROJECTID: SC13003
Interlocks and Trips on DCS

with
1 00GKB10-AP110A& Potable water pump- Interlock with Only one pump to
00GKB10-AP110B 1& Potable water each other remain in operation.
pump-2 If one pump trips,
other pump should
Manual control
selection in DCS.
2 00GKB10-AP110A& Potable water pump- 00GKB10- In case of tank level
00GKB10-AP110B 1& Potable water CL001Tank level extra low, the pump
pump-2 transmitter in operation shall trip
and either pump
shall not turn on
(start-permissive)

PROJECTID: SC13003
Checklist for Pumps

1 00GKB10-AP110A Potable Water Pump
2 00GKB10-AP110B Potable Water Pump
pumps -00GKB10-AP110A.

and whether tight
coupling guard.
coupled condition.
requirement.
any.

PROJECTID: SC13003

1 00GKB10-AA001 Globe Valve
pneumatic control valves - 00GKC10-CG001

these valves
and whether tight
the requirement.
air release, etc.

PROJECTID: SC13003
N. SERVICE WATER SYSTEM :
Objective
The Plant Service water system is supplied to provide / meet all the Service water requirements of the
CCPP, ie. at warehouse, workshop, GTG 1 and 2, HRSG 1 and 2, STG, Fuel Gas Compressor. The system
consists of Service (cum Fire) water storage tank, service water pumps (1 w + 1 s) to pump service water
from tank to various battery limits in the CCPP with a rated flow of 4 m3/hr and pressure of 4 barg, and
all other required auxiliaries and accessories.
The Service water tank shall be filled and the normal operating level shall be maintained by a flow
control valve at inlet based on level transmitter measurement in the tank. One of the Service water
pumps (installed on the tank) shall operate continuously to feed service water at various points in the
CCPP at required pressure. A flow control valve is installed to ensure minimum flow re-circulation for
the pump. The service water pump shall also have protection from dry run by providing interlock with
tank level transmitter for low level trip.
Reference Documents
- P&ID of Service Water System (SC13003-C9001-U01-0018)

- O&M Manual for Service water pumps and motors

1 Electrical Power Service water pumps - ZUG 3 phase, 50 Hz, 400 V
(00SGA10-AP010A, 00SGA10- supply
AP010B)
control valves

PROJECTID: SC13003

1 Service water To inspect and check all the Visual inspection
piping joints in the line are
complete
3 Instrument Check the calibration Through individual 00PCB10-CF001,
calibrations ranges / settings of all the monitors / 00SGA10-CL001,
instruments communicators 00PCB10-CP005
coupled condition.
5 Pumps Check alignment between Use GA dwg and O&M 00SGA10-AP010A,
the pumps & motors, check Manual to verify 00SGA10-AP010B
flanged connections, seals, correctness of
foundation bolts installation
rotation, earthing,
vibrations during
operation.
6 Valves Check the operation of the Through manual override 00PCB10-CG001,

valves through manual option and from DCS 00PCB10-CG002
operation and through DCS system

PROJECTID: SC13003
1. The Service water tank is fed with service water tapped from the existing service water pipeline.
2. Operation of the inlet control valve station to be checked, locally and through DCS. (Details of
the procedure / check list for pneumatic control valves provided separately below).
3. The service water line connecting the tie-in point to the new CCPP service water tank to be
installed.
4. 2 nos. Service water pumps installed at the Service water tank shall be checked thoroughly first.
Before the start of the pumps, the suction valves to be turned open manually. All the necessary
checks required for the pumps to be carried out. (Details of the procedure / check list for pumps
be checked.
5. Minimum re-circulation valve installed on the pumps outlet return line shall be checked for
operation, locally and through DCS. (Details of the procedure / check list for pneumatic control
7. The service water piping to various points in the plant to be checked for leakages and supports.

1 00SGA10-AP010A Service water pump-1 Trip
2 00SGA10-AP010B Service water pump-2 Trip
3 00SGA10-CL001 Tank level transmitter 4 to 20 mA Set point 5.4 m
Level low 5.1 m
Level high 5.6 m,
6 00PCB10-CP005 Pressure transmitter 4 to 20 mA Pressure low 2 barg

PROJECTID: SC13003

Measurement Action
1 00SGA10- 00PCB10-CG002 Open/Close Based on tank level low and high
CL001Tank level Control valve Analog signals, the control valve shall
transmitter open / close
2 00PCB10- 00PCB10-CG001 Open/Close In case of pump flow less than
CF001Flow Control valve Analog minimum (3 m3/hr), the valve
transmitter shall open proportionally and
through the pump

with
1 00SGA10-AP010A& Service water pump- Interlock with Only one pump to
00SGA10-AP010B 1& Service water each other remain in operation.
pump-2 If one pump trips,
other pump should
Manual control
selection in DCS.
2 00SGA10-AP010A& Service water pump- 00SGA10- In case of tank level
00SGA10-AP010B 1& Service water CL001Tank level extra low, the pump
pump-2 transmitter in operation shall trip
and either pump
shall not turn on
(start-permissive)

PROJECTID: SC13003
Checklist for Pumps

1 00SGA10-AP010A Service Water Pump
2 00SGA10-AP010B Service Water Pump
pumps -00SGA10-AP010A.

and whether tight
coupling guard.
coupled condition.
requirement.
any.

PROJECTID: SC13003

1 00PCB10-AA001 Globe Valve
pneumatic control valves - 00PCB10-CG001

these valves
and whether tight
the requirement.
air release, etc.

PROJECTID: SC13003
O. FIRE FIGHTING SYSTEM :
Objective
The Fire Fighting System is provided as per statutory requirements of the plant. The system consists of
fire hydrant system, sprinklers, smoke detectors, deluge system, CO 2 extinguishers, and all other
required auxiliaries and accessories. This system is operated by a dedicated PLC based control panel and
signals are provided to plant DCS through Modbus communication only for monitoring purpose.
A separate fire control panel shall be provided for monitoring and operation of the fire fighting system
for the plant, the details of which are presented in another specific document related to fire fighting
system.
The details of the I/P addresses and various I/Os from the Fire fighting system panel to the DCS shall be
indicated separately in document related to Fire detection Panel and Detector datasheet - .
Pre-commissioning Checks and Commissioning Procedure
The O&M manual of the Fire Fighting system shall provide the guidelines for the start-up, pre-
commissioning, checks, commissioning procedure for the same. The OEM supplier shall provide
assistance and guidance for the commissioning of this system.

1 Electrical Power Firefighting panel inlet ZUG 3 phase, 50 Hz, 400 V
supply
power / signal transmitters

PROJECTID: SC13003
P. WASTE WATER TREATMENT SYSTEM :

PROJECTID: SC13003
Q. NITROGEN PURGE SYSTEM :
Objective
A nitrogen purge system is provided in the CCPP for purging requirement of all equipments in the plant
and for storage of the equipments for longer durations. The system consists of a nitrogen bottle storage
rack, pressure regulators, and all other required auxiliaries and accessories.
The nitrogen line pressure regulating valves are self-actuated type with pressure set point as required at
the respective equipments (for purging). Pressure transmitter and gauge are provided to ensure safe
operation of nitrogen system.
Pre-commissioning Checks and Commissioning Procedure
The O&M manual of the Nitrogen purge system shall provide the guidelines for the start-up, pre-
commissioning, checks, commissioning procedure for the same. The OEM supplier shall provide
assistance and guidance for the commissioning of this system.
Reference Documents
- P&ID of Nitrogen Purge System (SC13003-C9001-U01-0020)

- O&M Manual for Nitrogen purge system
- O&M Manual for Valves

1 Electrical Power -- -- --
2 Instrument Pressure transmitters, switches, ZUG 24 V DC
power / signal solenoid valves

PROJECTID: SC13003

1 00QJA10-CP002 Pressure transmitter High Alarm

with
1 00QJA10-AA100 Solenoid valve 00QJA10-CP003 In case pressure is
high, the solenoid
valve shall close.

PROJECTID: SC13003
R. Electro Chlorination System

PROJECTID: SC13003
S. Sea Water Intake System
Checklist for Motorized Valve :

1 00PAE10-AA001 Butterfly Valve
motorized valves

these valves
and whether tight
gearbox
the requirement.
Note: For Sea water Intake system refer vendor documents

PROJECTID: SC13003

SC13003-C9001-U10-0002-Commissioning Plan Procedure For MBOP - 24-08-2015 PDF

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PROJECT ENGINEERING DOCUMENT

DOCUMENT SUBMISSION STATUS:

00 28-AUG-15 FOR APPROVAL MP PSB PSB

REV DATE DESCRIPTION PREPARED CHKD APPD

EPC CONTRACTOR CONSULTANT

120 MW Tanjung Uncang Combined Cycle Power Project,

COMMISSIONING PLAN & PROCEDURE FOR MBOP

DOCUMENT NO REV DATE PAGES

Main Cooling water system

PROJECT: 120MW COMBINED CYCLE POWER PLANT

MBOP SYSTEMS FOR SIMPLE CYCLE MODE OF OPERATION OF THE CCPP:

A. COMPRESSED AIR SYSTEM :

- P&ID of Service and Instrument Air System (SC13003-4500-U01-0004)

Inputs Required for Commissioning / Operation of the System

SN Input @ terminal point By Particulars / Remark

PROJECT: 120MW COMBINED CYCLE POWER PLANT

SN Equipment Check How Remark

1. The air compressors to be powered from the panel room.

PROJECT: 120MW COMBINED CYCLE POWER PLANT

The following alarms are to be checked in the DCS -

SN Tag No Equipment Indication type Remarks

The following closed loops are to be checked in the DCS -

SN Input Control Variable Control Logic

B. CLOSED COOLING WATER SYSTEM :

PROJECT: 120MW COMBINED CYCLE POWER PLANT

Inputs Required for Commissioning / Operation of the System

SN Input @ terminal point By Particulars / Remark

SN Equipment Check How Remark

PROJECT: 120MW COMBINED CYCLE POWER PLANT

PROJECT: 120MW COMBINED CYCLE POWER PLANT

The following alarms to be checked in the DCS -

The following interlocks and trips to be checked in the DCS -

PROJECT: 120MW COMBINED CYCLE POWER PLANT

SN. TAG NO. EQUIPMENT CONFIRM

2 01PGB10-AP110B, Closed Circuit cooling water pump-2 for GTG1

3 02PGB10-AP110A, Closed Circuit cooling water pump-1 for STG

4 02PGB10-AP110B, Closed Circuit cooling water pump-2 for STG

5 03PGB10-AP110A, Closed Circuit cooling water pump-1 for GTG2

6 03PGB10-AP110B Closed Circuit cooling water pump-2 for GTG2

SN Particular Check Confirm Remark

The system consists of -

- P&ID of DM Water System (SC13003-C9001-U01-0013)

Inputs Required for Commissioning / Operation of the System

SN Input @ terminal point By Particulars / Remark

PROJECT: 120MW COMBINED CYCLE POWER PLANT

SN Equipment Check How Remark

6 Valves Check the operation of the Through manual 00GHC10-CG001

PROJECT: 120MW COMBINED CYCLE POWER PLANT

Alarms, Interlocks and Trips Checks

The following alarms are to be checked in the DCS -

SN Tag No Equipment Indication type Remarks

SN Input Control Variable Control Logic

PROJECT: 120MW COMBINED CYCLE POWER PLANT

SN Tag No. Equipment Interlock / Trip Logic

PROJECT: 120MW COMBINED CYCLE POWER PLANT

SN. TAG NO. EQUIPMENT CONFIRM

SN Particular Check Confirm Remark

PROJECT: 120MW COMBINED CYCLE POWER PLANT

SN. TAG NO. EQUIPMENT CONFIRM

SN Particular Check Confirm Remark

PROJECT: 120MW COMBINED CYCLE POWER PLANT

- P&ID of Fuel Gas System (SC13003-4100-U01-0001)

Inputs Required for Commissioning / Operation of the System